Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F27—FURNACES; KILNS; OVENS; RETORTS
  • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
  • F27D1/00—Casings; Linings; Walls; Roofs
  • F27D1/16—Making or repairing linings increasing the durability of linings or breaking away linings
  • F27D1/1626—Making linings by compacting a refractory mass in the space defined by a backing mould or pattern and the furnace wall
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
  • C10B29/00—Other details of coke ovens
  • C10B29/06—Preventing or repairing leakages of the brickwork
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F27—FURNACES; KILNS; OVENS; RETORTS
  • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
  • F27D1/00—Casings; Linings; Walls; Roofs
  • F27D1/10—Monolithic linings; Supports therefor

Definitions

• This invention relates generally to repair of Silica brick heating walls in a refractory furnace, and more specifically, in a non-limiting and exemplary embodiment, to the repair of Silica brick heating walls, roof and/or corbel areas in a coke oven.
• coke is produced in a coke oven battery which includes a plurality of side-by-side coking chambers or ovens which are separated from each other by heating walls, the heating walls extending the full length of the chambers .
• the ovens are sometimes ' referred to as "pushing ovens" because after the coking process, the coke is pushed in the lengthwise direction out of the ovens.
• a typical coke oven installation might include, for example 30 to more than 100 individual coking chambers or ovens in side- by-side relationship, with each chamber being from 3 to 7 meters high, typically 14 or more meters long, and approximately 1 A - 1 meter wide.
• Each heating wall is typically built up from a number of horizontally extending courses of silica bricks, the bricks being assembled to define vertically and/or horizontally extending internal flues or vents (and other passages) within the heating walls .
• the invention relates to a method of repairing a refractory brick wall in a furnace comprising:
• steps (c) through (f ) are carried out to form a first section of the new wall or portion thereof of a height less than a finished height for the new wall or portion thereof; and repeating steps (c) through (e) to form one or more additional sections, stacked one on the other, until the finished height is achieved.
• the invention in another aspect, relates to a method of replacing all or a portion of a Silica brick heating wall in a coke oven, the heating wall located between a pair of adjacent ovens and containing at least one flue passage, the .method comprising: (a) demolishing the wall or portion thereof;
• FIGURE 1 is .a schematic side elevation of a plurality of side-by-side coking ovens, with repair bulkheads installed in the ovens on either side of a wall to be repaired;
• FIGURE 2 is a schematic plan view of the ovens shown in Figure 1;
• FIGURE 3 is a plan view similar to Figure 2 but with insulation blankets installed in the repair area;
• FIGURE 4 is a plan view similar to Figure 3 but with supports installed adjacent an interface with the wall to be repaired;
• FIGURE 5 is an end elevation of the repair area within the oven, with additional, optional, length-wise bracing installed;
• FIGURE 6 is a partial perspective view of exemplary forms employed in the process of this invention.
• FIGURE 7 is a partial perspective view of part of a repaired wall section, showing outer and inner forms installed in a lower stage, with refractory castable material poured therein;
• FIGURE 8 is a schematic representation illustrating how a new wall section is built up and poured in stages
• FIGURES 9 and 10 are schematic representations illustrating how an internal flue passage is built up and poured in stages.
• FIGURES 11-16 are views of different specialty pre- engineered forms that may be used in the repair or replacement process. DETAILED DESCRIPTION OF THE INVENTION
• one section 10 of a larger coke oven is shown to include a series or plurality of substantially parallel, side-by-side heating chambers or coking ovens 12, 14, 16 and 18 separated by heating walls 20, 22, 24, 26 and 28.
• a floor, or corbel area is designated by numeral 30, it being understood that the floor construction is more complex than shown here.
• a roof 32 extends across the tops of the heating walls. It will also be understood that the Figures illustrate only a small section of the coke oven, and in a somewhat simplified manner for ease of understanding of this disclosure.
• the heating walls are each shown to include a plurality of vertically-oriented flues 34 within the interior of the walls .
• additional passages e.g., horizontal flue sections, horizontal or vertical piping and the like
• Each heating wall is constructed of laid up Silica bricks, and for purposes of this disclosure, it is assumed that bricks in the heating wall 24 are damaged, thus requiring reconstruction of at least a portion of the heating wall 24 as described further below.
• bulkheads 42, 44 are constructed within the adjacent chambers or ovens 16, 18, beyond the area to be repaired.
• the bulkheads 42, 44 are composed of bricks 46, e.g., 4.5 x 9 x 3 inch insulating (to 1800 0 F or higher) clay bricks, laid up as best seen in Figure 1. The bricks may be sawed to fit as necessary, and laid dry and tight against one another.
• the bulkheads extend substantially to the roof, effectively isolating the area to be repaired.
• So-called "headache" racks are installed prior to entering the oven chambers to provide protection from falling debris during and after demolition of the damaged wall area.
• These racks may comprise metal netting or similar, suspended from the roof or by other suitable means .
• insulation which may take the form of ceramic fibers blankets 48, 50 may be applied to the exposed walls of adjacent heating walls, and across the bulkheads 44, 46 ( Figure 3) .
• the ceramic fiber blankets may be applied in two 1 inch or 1.5 inch layers with overlapping seams, and temporarily secured in any appropriate manner. It will be appreciated that the insulation should either be omitted along the solid wall 40, or removed therefrom in stages, as the reconstruction progresses . The insulation is particularly beneficial since the adjacent working ovens remain heated to an elevated temperature during the repair process .
• braces 52 are installed between adjacent heating walls 22, 26 and that part of the wall 24 that remains, i.e., that does not require reconstruction.
• Each brace 52 may include a pair of threaded, telescoping rods 54, 56 and a tightening nut 58, permitting the brace to be extended into contact with adjacent wall surfaces.
• braces 52 as are needed can be vertically spaced from near the floor to near the ceiling, and similar groups of braces may be located as desired. It will be appreciated that ceiling supports may also be utilized as needed. These braces or supports will stabilize the existing walls and flues.
• a vertically oriented "buck stay” (I-Beam) 60 may optionally be installed remote from the existing flue 62 of the repair wall, as best seen in Fig. 5.
• One or more adjustable, horizontally-oriented brace supports 64 may extend between the brick stay 60 and existing flue wall 62, thus preventing the existing flue wall from moving out toward the opening created during demolition.
• the supports 64 may again may include telescoping, threaded rods 66, 68 and an expansion nut 70, with a broader support portion 72 adapted to engage the existing wall.
• the outer wall forms 74,76 may be constructed of plywood, aluminum, a laminate construction of wood and metal (for example, plywood on the inner side and a metal such as aluminum on the outer side), or other suitable material.
• the inner forms are preferably wood, fiberboard, cardboard , PVC or other suitable consumable material that will burn off when the repaired oven is heated upon completion of the reconstruction work.
• the form work is constructed in stages, with forms having a height of 24-30 inches preferred, and a length equal to the applicable length of the wall to be repaired.
• the first stage of the construction involves the placement of external wall forms 74 and 76, in combination with consumable "box" forms 78, 80 and 82 located within the confines of the outer forms to ' thereby define the discrete internal, vertically-oriented flue (or other) passages.
• additional form work or bracing may be added as necessary to either provide support for the internal forms or to define additional sub-passages within the flues (see, for example, braces 83 in Figures 6 and 7.
• the forms must be set so that the poured wall will be flush with the existing brick work.
• the forms For the internal flues, the forms must be set so that the poured wall will be about l/8 th inch to the inside of existing brick work.
• the castable refractory material 84 is pumped into the enclosed area, and around the internal flue forms, as shown in Figure 7. It will be appreciated that refractory material may also be pumped within certain defined areas of the internal box forms, as shown for example in Figure 7, where pipe 86 is surrounded by refractory material within a smaller boxed-in-portion 88 of the larger flue passage.
• the refractory material may be a product sold under the name FosKast FS-P available from Fosbel, Inc., of Brook Park, Ohio, USA. This is a fused, silica-based, zero expansion , pumpable, castable designed for severe service applications requiring high mechanical strength and resistance to thermal shock, with a minimum service temperature of 2800 0 F (1538°C) .
• the material is installed in the formwork preferably by pumping into the formwork from above the respective form sections, using an industrial concrete vibrator to ensure uniformity of material while pumping. Thereafter, a second stage form construction substantially identical to that described above (or modified as needed) , is stacked on top of the first stage, and the pumping process repeated.
• Ceramic welds are installed at the tie in joints.
• This process of stacking forms and pouring/curing the refractory material is repeated until the new wall reaches substantially the height of the roof 32.
• This procedure is shown schematically in Figure 8 where forms A, B, C, and D are stacked in succession in respective stages 1-4.
• Figures 9 and 10 show how a similar stacking arrangement is used to form an internal flue or chimney passage, using multiple box forms 78, for example. The number of stages will depend on the height of the wall and the size of the individual form sections. At the roof level, there are two options for completing the wall .
• the formwork is brought as close as possible to the roof and then a second phase of pumping takes place to pump the roof section.
• a portion of the roof corresponding to the repaired wall area is removed and the framework will then extend through the roof opening, with the adjacent roof sides forming a part of the formwork.
• the forms will be sized, such that the final pour will be substantially flush with the outer surface of the roof.
• Figures 11 -16 are illustrative in this regard.
• Figures 11-13 show a square form 90 (twenty four inches on a side) composed of a solid side panel 92 surrounded by a solid frame 94, in combination with internal braces shown at '96, 98 for example.
• Figures 14-16 show a rectangular elongated outer form 100 (48" by 24"), also composed of a single side panel 102 surrounded by a solid frame 104, and also utilizing interior braces 106, 108.
• One end of the form is angled or bent at 110, it being understood that this configuration is merely exemplary of any number of form shapes that may be required in any given field application. As no two installations are alike , each installation must be individually engineered to encompass all of different heating flue designs and interior brickwork designs and dimensional characteristics.
• the repair/reconstruction process described herein has many advantages over the prior practice of replacing the damaged silica bricks on an individual basis. For example, typical long lead time brick delivery delays are eliminated; the reconstruction is far less complex labor intensive; shorter heat up cycle, the process easily accommodates expanded oven walls , and existing roofs can be preserved if desired. In addition, lost production days and hence lost production costs are reduced .

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• Engineering & Computer Science (AREA)
• Chemical & Material Sciences (AREA)
• Mechanical Engineering (AREA)
• General Engineering & Computer Science (AREA)
• Materials Engineering (AREA)
• Oil, Petroleum & Natural Gas (AREA)
• Organic Chemistry (AREA)
• Furnace Housings, Linings, Walls, And Ceilings (AREA)

Priority Applications (11)

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Publications (1)

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• 2008
  • 2008-10-29 EP EP08844763.6A patent/EP2203702B1/en not_active Not-in-force
  • 2008-10-29 RU RU2010122057/02A patent/RU2480697C2/ru not_active IP Right Cessation
  • 2008-10-29 PL PL08844763T patent/PL2203702T3/pl unknown
  • 2008-10-29 WO PCT/GB2008/003686 patent/WO2009056843A1/en active Application Filing
  • 2008-10-29 KR KR1020107009277A patent/KR20100075567A/ko not_active Application Discontinuation
  • 2008-10-29 CA CA2703759A patent/CA2703759A1/en not_active Abandoned
  • 2008-10-29 US US12/740,888 patent/US20110241237A1/en not_active Abandoned
  • 2008-10-29 BR BRPI0818840 patent/BRPI0818840A2/pt not_active IP Right Cessation
  • 2008-10-29 AU AU2008320668A patent/AU2008320668B2/en not_active Ceased
  • 2008-10-29 MX MX2010004749A patent/MX2010004749A/es active IP Right Grant
  • 2008-10-29 JP JP2010531578A patent/JP2011503254A/ja active Pending
  • 2008-10-29 CN CN200880114468A patent/CN101842655A/zh active Pending
  • 2008-10-31 TW TW097142291A patent/TW200938796A/zh unknown
• 2010
  • 2010-03-02 ZA ZA2010/01516A patent/ZA201001516B/en unknown

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